Hydrogen Gas Generator for on Mars Methane Production

Human Mars missions require fuel to return to Earth and bringing fuel is not sustainable for long-duration campaigns. A solution for on-Mars fuel production could be available in-situ from mining water and electrolysis but it requires a high level of complexity and multiple missions to accomplish. A different solution is needed for early and mid-term missions. A possible solution is to combine hydrogen and atmospheric CO2 producing methane through the Sabatier process. To demonstrate this process before water mining and electrolysis is available, H2 could be provided by a solid gas generator. Gas generation in space applications has been under development, primarily in inflatable aerodynamic decelerators. In this case, utilizing solid gas generators offers a more efficient volume-mass to weight form factor, reduces complexity, and provides long-term hydrogen storability compared to cryogenics. Overall system performance will be judged against bringing tanks of liquid water from earth, along with an electrolysis system and the power necessary to produce H2 gas. Several solid hydrogen-containing compounds were considered. Those selected have been researched for industrial H2 generation applications, but not yet adapted for space, specifically methane propellant production, therefore, both the level of innovation for this application and the return of investment is high. The compounds were down selected based on critical constraints and metrics. Sodium borohydride and ammonia borane, were flagged for further consideration to ultimately select one compound for procurement and demonstration of H2 generation. After the ideal compound is selected, a storage and gas-usage system (valves, filters, flowmeter, tank, etc.) will be designed with the potential for optimization, scalability, and adaptability. Then, a proof of concept system will be fabricated, reactants procured, and a bench test will be performed to assess yield and system efficiency by measuring H2 production.

It is paramount to have available re-fueling capabilities for on-Mars missions, the access to hydrogen is key for methane production. This project aims to design and optimize a mass and volume efficient H2 solid gas generator as the hydrogen source.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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